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| United States Patent |
5,337,951
|
|
Roccaforte
|
August 16, 1994
|
Sturdy sandwich carton
Abstract
A carton for fast food items is provided. The carton has a polygonal bottom
panel with four generally rectangular side wall panels foldably attached
to the edges thereof. A major top closure panel is foldably connected to
one of the side wall panels, and a minor top closure panel is foldably
connected to the opposite side wall panel. The minor top closure panel
carries a closure tab having bilateral locking wings. A slot is provided
in the major top closure panel for receiving the closure tab. The carton
includes corner closing, backfolded, double layer webs at each corner.
Each web is foldably connected to a first associated side wall panel at a
perforated fold scoreline collinear with the edge of that panel, and to an
adjacent side wall panel along an angled perforated or cut fold scoreline
extending outwardly at approximately 45.degree. from each corner of the
bottom wall panel. The present invention also encompasses a die cut blank
for forming the carton.
The present invention also includes a forming fixture for erecting the
carton at the point of use. The forming fixture has a base and two pairs
of forming walls, each wall angling upwardly and outwardly from the base,
one pair of walls being disposed at an angle of approximately 45.degree.
to the base, while the other pair of walls is at approximately a
60.degree. angle.
| Inventors:
|
Roccaforte; Harry I. (Chicago, IL)
|
| Assignee:
|
Waldorf Corporation (St. Paul, MN)
|
| Appl. No.:
|
925608 |
| Filed:
|
August 5, 1992 |
| Current U.S. Class: |
229/186; 229/102; 229/150 |
| Intern'l Class: |
B65D 005/24 |
| Field of Search: |
229/114,149,150,152,102,40,186
|
References Cited
U.S. Patent Documents
| Re32956 | Jun., 1989 | Schuster.
| |
| 413784 | Oct., 1889 | Hotchkiss.
| |
| 2781159 | Feb., 1957 | Copeman.
| |
| 2800268 | Jul., 1957 | Mathews.
| |
| 2944295 | Jul., 1960 | Sloan.
| |
| 2956720 | Oct., 1960 | Rindal.
| |
| 3000275 | Sep., 1961 | Sevison.
| |
| 3146933 | Sep., 1964 | Moore.
| |
| 3454209 | Jul., 1969 | Persson.
| |
| 3782071 | Jan., 1974 | Hagedorn.
| |
| 4003515 | Jan., 1977 | Steele | 229/150.
|
| 4171763 | Oct., 1979 | Card | 229/150.
|
| 4199097 | Apr., 1980 | Christensson | 229/186.
|
| 4295839 | Oct., 1981 | Baker et al.
| |
| 4447004 | May., 1984 | House et al.
| |
| 4451001 | May., 1984 | Webinger | 229/186.
|
| 4472896 | Sep., 1984 | Brauner et al.
| |
| 4575000 | Mar., 1986 | Gordon et al.
| |
| 4830270 | May., 1989 | Holmes | 229/150.
|
| 4836439 | Jun., 1989 | Hart.
| |
| 4925019 | May., 1990 | Ganz et al. | 229/40.
|
| 4930639 | Jun., 1990 | Rigby | 229/186.
|
| 4951868 | Aug., 1990 | Mode.
| |
| 5033668 | Jul., 1991 | Cohen et al.
| |
| 5125565 | Jun., 1992 | Rogers | 229/150.
|
| 5183201 | Feb., 1993 | Gulliver | 229/186.
|
Primary Examiner: Elkins; Gary E.
Assistant Examiner: McDonald; Christopher
Attorney, Agent or Firm: Dorsey & Whitney
Claims
What is claimed is:
1. A generally polygonal carton comprising:
a polygonal bottom wall having at least a pair of adjacent edges and a
corner between said pair of adjacent edges;
a side wall foldably attached to each of said adjacent edges, said side
walls arranged in two sets of opposed side walls, each side wall having
side edges and an upper edge extending between said side edges;
corner means foldably connected to the carton generally between adjacent
side walls at each corner of the bottom wall for substantially closing the
corners of the carton and comprising web panels, each being foldably
connected to the side edges of the side walls of one of said two sets of
opposed side walls and to the side walls of the other set of opposed side
walls along a fold line extending outwardly at an angle from each corner
of the bottom wall;
top closure means for closing the top of said carton comprising an
underlying top closure panel foldably connected along the upper edge of
one of said opposed side walls and an overlying top closure panel foldably
connected along the upper edge of the opposite side wall; and
locking means for releasably locking the top closure means.
2. The carton according to claim 1, wherein said locking means comprises a
closure tab carried by said underlying top closure panel and a tab
receiving opening in said overlying top closure panel.
3. The carton of claim 2 wherein said closure tab includes a tab center
defined by a pair of angular closure fold scorelines, a free edge and a
connection fold scoreline, and a pair of closure wings connected to said
tab center along said closure scorelines.
4. The carton of claim 3 wherein the tab center is foldably connected with
said underlying top closure panel along the connection fold scoreline.
5. The carton of claim 3 wherein said tab center has a minimum width
dimension at its free end and each of said wings has a maximum width
dimension extending in a direction perpendicular to its respective angular
closure fold scoreline and said tab receiving opening has a length
dimension measured along a line parallel to, and at least as long as, said
connection fold scoreline and at least one width dimension at least as
long as said maximum width dimension.
6. The carton of claim 5 wherein said tab receiving opening has a pair of
ends each having a width dimension at least as long as said maximum width
dimension.
7. A single-piece blank for forming a carton, said blank comprising;
a polygonal bottom wall panel having at least a pair of adjacent edges and
a corner between adjacent edges;
a side wall panel foldably attached to each of said adjacent edges of the
bottom wall panel, said side wall panels having side edges and being
arranged in at least two sets of opposed side wall panels;
corner means for substantially closing the corners of the carton formed
when the blank is erected, said corner means comprising web panels
foldably connected to each side edge of the side wall panels of one set of
opposed side wall panels and to the side wall panels of the other set of
opposed side wall panels along an angular fold line extending outwardly
from each corner of said bottom panel; and
top closure means for closing the carton formed when said blank is erected,
said top closure means comprising a first top closure panel foldably
connected to one of said side wall panels and having a free edge and a
second top closure panel foldably connected to the side wall panel
opposite to the side wall panel carrying said first top closure panel.
8. The blank according to claim 7 and locking means for releasably
connecting said first and second top closure panels.
9. The blank according to claim 8, wherein said locking means comprises a
tab carried by said first top closure panel along said free edge and a tab
receiving opening in said second top closure panel.
10. A carton for temporarily containing and protecting fast food items,
wherein the carton can be converted simply and easily into a substantially
planar tray for supporting the contents during consumption, comprising:
a polygonal bottom wall having a periphery defined by bottom edges, each
having a pair of ends and each intersecting an adjacent edge at each of
its ends to define a corner of the bottom wall;
a first and second pair of opposed side walls foldably attached to a
portion of the periphery of the bottom wall, each side wall of the first
pair having two opposed side edges substantially perpendicular to the
portion of the periphery of the bottom wall at which the side walls of the
first pair are attached and substantially collinear with the portion of
the bottom wall periphery at which the side walls of the second pair are
attached;
a single web panel at each corner of the bottom wall, each being foldably
connected to one of the side edges of the side walls of the first pair of
opposed side walls and foldably connected to the side walls of the second
pair of side walls along a fold line extending at an angle diagonally
outwardly from each corner of said bottom panel; and
top closure means for closing the top of said carton comprising a first top
closure panel foldably connected to one of the side walls of the second
pair and having a free edge, and a second top closure panel foldably
connected to the side wall panel opposite to the other side wall of the
second pair, said first top closure panel carrying a closure tab and said
second top closure panel carrying a closure tab receiving opening.
11. The carton according to claim 10, wherein said closure tab includes a
tab center defined by a pair of angular closure fold scorelines, a free
edge and a connection fold scoreline, a pair of closure wings being
connected to said tab center along said closure scorelines, the closure
tab being foldably connected to the free edge of the first top closure
panel along the connection fold scoreline and having a minimum width
dimension along its free edge, each of said wings having a maximum width
dimension extending in a direction perpendicular to the associated angular
closure fold scoreline, said tab receiving opening having a length
dimension measured along a line parallel to, and at least as long as, said
connection fold scoreline and at least one width dimension at least as
long as the maximum width dimension of said wings.
12. A carton for temporarily containing and protecting fast food items,
wherein the carton can be converted simply and easily into a substantially
planar tray for supporting the contents during consumption, said carton
comprising a bottom wall with a peripheral edge and corners, and pairs of
adjacent side walls foldably connected to the bottom wall about the
peripheral edge, each of said pairs of adjacent side walls including one
side wall substantially free of fold lines and one side wall with web
regions each defined by a fold line generally perpendicular to the
peripheral edge, the side walls of each of said pairs of adjacent side
walls being connected along a fold line extending diagonally outwardly
from the corners of the bottom wall, the surface area of the side walls
substantially free of fold lines being greater than the surface area of
the side walls with the web regions less the surface area of the web
regions, a first closure panel with a free edge foldably connected to one
of the side walls substantially free of fold lines, and a second closure
panel foldably connected to an opposed another one of the side wall panels
substantially free of fold lines, said first closure panel carrying a
closure tab and said second closure panel carrying a closure tab receiving
opening.
13. The carton according to claim 12, wherein said closure tab includes a
tab center defined by a pair of angular closure fold scorelines, a free
edge and a connection fold scoreline, a pair of closure wings being
connected to said tab center along said closure scorelines, the closure
tab being foldably connected to the free edge of the first closure panel
along the connection fold scoreline and having a minimum width dimension
along its free edge, each of said wings having a maximum width dimension
extending in a direction perpendicular to the associated angular closure
fold scoreline, said tab receiving opening having a length dimension
measured along a line parallel to, and at least as long as, said
connection fold scoreline and at least one width dimension at least as
long as the maximum width dimension of said wings.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to paperboard cartons. More particularly, the
present invention relates to a paperboard carton or container for fast
food items, the blank for forming the carton, and a point of use forming
fixture for facilitating the erection and filling of cartons at the point
of use. The invention also relates to the method of using the fixture.
2. Description of the Prior Art
In recent years, there has been a proliferation of fast food restaurants.
Typically, the food items sold at such restaurants include individually
packaged hamburgers or other sandwiches, which are unwrapped or opened by
the consumer upon purchase. A number of containers have been used for this
purpose, ranging from polystyrene clamshell type cartons to simple paper
wrapping.
Even more recently than the rise of the popularity of convenience or fast
food restaurants, there has been increased recognition of the need to
conserve natural resources. Thus, there is pressure upon the paper and
paperboard packaging industries to increase the efficient use of stock
material and to use recyclable material for disposable packages or
cartons. Rising prices are also driving the quest for efficiency and
economy.
These demands, and the need to provide an attractive, sturdy package or
carton for consumer goods, including fast food items, have created the
need for a sturdy, simple recyclable or disposable carton for packaging
such food items that can be cost efficiently manufactured, rapidly and
easily erected and filled at the point of use, closed and locked to
adequately protect the contents, and easily opened by the consumer.
Although commercially available food item cartons, and methods of forming
the cartons, have improved, there are some problems which have remained
unaddressed. A principal problem is providing a carton, and blank
therefor, which minimizes the use of valuable resources while at the same
time maintaining the food items in as clean and secure a condition as
possible after the purchase thereof and prior to consumption. Handling of
some commercially available packages, such as a simple paper wrapping, can
dislodge the food item from its container, thus contaminating it. It is
highly desireable that a food item package or carton be strong enough to
adequately protect the contents, yet be easy to open. It is also
desireable that a container or carton for fast food items be quickly and
easily erected and filled at the point of use. With current packaging
methods, ease of use, efficient manufacture and safety are not enhanced to
an optimum degree.
U.S. Pat. No. 2,781,159 (to Copeman) discloses a moisture impervious
container for protecting the contents. The Copeman container discloses
scorelines around the edges of the side wall panels, whereby the
peripheral edge portions of two sidewall panels automatically fold flatly
against corresponding edge portions of the other two sidewall panels. This
structure is directed to providing a rigid corner construction and
hermetic seal. The carton of the Copeman patent is not specifically
directed to containing food items and does not disclose a carton which is
easily opened and closed. Rather, the top wall panel of the carton simply
overlies the upper edge portions of the side walls and includes an extreme
end flap that is joined to one of the side wall panels when the carton is
closed.
U.S. Pat. No. 2,956,720 (to Rindal) discloses a locking structure including
a male locking member having an arrow-like configuration and a slit line
female locking member for receiving the male locking member. U.S. Pat. No.
4,472,896 (to Brauner et al.) discloses a carton for food products such as
hamburgers. The carton is one of the aforementioned clamshell type cartons
and includes a locking tab and slit arrangement for dosing the carton.
None of the above-noted patents discloses a fixture or folding apparatus
for facilitating the erection of a carton at the point of use. U.S. Pat.
Nos. 3,000,275 (to Sevison), 3,146,933 (to Moore), 3,782,071 (to Hagedorn)
and 4,295,839 (to Baker et al.) disclose methods and apparatus for forming
cartons or trays. The Moore patent discloses a carton having flanges to
reinforce the corners. The flanges are hinged to each other on diagonal
foldlines extending obliquely from the corners. The apparatus for forming
the blank into the shaped carton is a female die wherein the sidewalls of
the carton are angled upwardly as the carton blank is forced into the
female die. Somewhat similarly, the Baker et al. patent discloses a tray
forming apparatus that includes a forming head with a cavity for causing
the tray side walls to be erected and the tray gusset corners to be flat
against adjacent side walls.
The Sevison patent, particularly FIGS. 16 and 17, and the Hagedorn patent,
particularly FIG. 8, disclose that the end or side wails of a blank may be
successively folded to positions at right angles to the bottom wall. With
specific regard to the Sevison patent, the carton end walls first ride
over a first curved edge portion of a jig whereby they move upwardly to a
position substantially perpendicular to the bottom wall of the blank.
Thereafter, the side walls of the box or carton ride over another curved
edge portion of the jig to affect folding.
While the immediately preceding four patents provide useful apparatus for
forming a carton, in each case the forming apparatus is part of a large,
complex machine which is unsuitable for use in a fast food restaurant, or
in any restaurant environment. Additionally, none of the above-noted
patents discloses a forming or erecting fixture wherein the forming faces
of the fixture walls are at specific angles to induce folding of the wall
panels of a carton blank in a specific order or sequence, or a recess or
slot between adjacent fixture walls to accommodate a carton that includes
backfolded webs or gussets.
Accordingly, there is a need for a sturdy, simple, cost efficient,
disposable carton for containing fast food items, and for a forming
fixture which may be conveniently used in a restaurant in the food service
industry to facilitate the erecting, filling and closing of the carton
prior to sale of a food item to the consumer.
SUMMARY OF THE INVENTION
In accordance with the present invention, a carton for consumer items,
particularly fast food items, is provided. The carton comprises a
generally rectangular and substantially lockable carton having a polygonal
bottom panel with four generally rectangular side wall panels foldably
attached to the edges thereof. A major top closure panel is foldably
connected to the upper free edge of one of the side wall panels, and a
minor top closure panel is foldably connected to the upper free edge of
the opposite side wall panel. The minor top closure panel has a free edge
with a generally central relieved area and a closure tab, having bilateral
locking wings, is foldably connected in the generally central region of
the relieved area. An opening is provided in the major top closure panel
for receiving the closure tab. Between each pair of opposed side wall
panels, i.e., at each corner of the erected carton, the carton includes
corner closing means. The corner closing means comprises a back folded,
double layer web at each corner. Each web is foldably connected to the
associated side wall panels at a perforated fold scoreline collinear with
the side edges of two panels, and is connected to the adjacent side wall
panels along an angled, perforated or cut fold scoreline extending
outwardly at approximately 45.degree. from each corner of the bottom wall
panel. The present invention also encompasses a die cut blank for forming
the carton.
The present invention also includes a forming fixture for erecting and
filling the carton at the point of use, typically a fast food restaurant.
The forming fixture comprises a base member with raised curb plate
supports fixedly mounted thereon. Four angled forming walls, arranged in
two opposed and generally similar pairs, each pair being comprised of two
similarly angled forming walls, are attached to a curb plate fixed to the
curb plate supports. Each forming wall has an inside forming face, a
bottom edge, a top edge, and two opposed side edges. The four walls define
an open, central, carton bottom receiving cavity. Each wall tapers or
angles upwardly and outwardly from the base, and the forming faces of one
pair of walls are disposed at an angle of approximately 45.degree. with
respect to the base, while the forming faces of the other pair of forming
walls are at approximately a 60.degree. angle. At each corner of the
receiving cavity, the curb is provided with a backfold web receiving slot.
Each slot extends outwardly from the cavity toward the periphery of the
base, along the sides of the 60.degree. forming walls.
One feature of the carton of the present invention is a double thickness
corner backfold web at each corner of the carton of the present invention
in combination with a closure means and locking means. A web panel is at
each end of two of the side panels. The webs are foldably connected to the
associated side wall panel at a fold line which is parallel to the free
edge of the webs and which is coincident or collinear with the edge of
that side wall panel when the carton is erected. The backfold webs are
connected to the other two side walls of the carton along an angled cut
scoreline that extends outwardly from each corner of the bottom panel.
This feature makes the carton of the present invention very sturdy when
erected and suitable for use for relatively heavy food items such as
hamburgers. Even if the package rotated on its side by a consumer or a
restaurant worker, the sandwich will not push any of the side walls
outwardly.
A further feature of the present invention is an improved lock means for a
food carton.
Accordingly, it is an object of the present invention is to provide a
sturdy, yet easily erected, filled, locked and opened carton for
containing fast food items.
Another object of the present invention is to provide a package or carton
for food items whereby, during handling of the carton, damage to the
contents is minimized.
Yet another object of the present invention is to provide a forming fixture
or jig for erecting and filling the carton at the point of use.
A further object of the present invention is to provide a simple, cost
efficient paperboard carton for containing a food item whereby the carton
protects the food item during vending, yet may be rapidly and easily
erected and filled at the point of use, and wherein typical manufacturing
operations may be used to form the blank for the carton.
Still another object of the present invention is to provide a carton for
containing food items which may be erected rapidly and easily, closed and
locked for distribution to consumers, yet may be opened easily by the
consumer and used as a tray for supporting a food item during its
consumption.
In use, the blank for forming the carton of the present invention is
die-cut and may be shipped, partially glued or flat, to the point of use.
The carton of the present invention is erected and filled at the point of
use by placing the flat blank, exterior down, on top of the forming
fixture with the bottom panel aligned with the cavity of the fixture and
with the carton side wall panels having the backfold webs aligned over the
60.degree. forming faces of the fixture. A sandwich or other food item is
placed on top of the bottom panel and the weight of the sandwich will
begin to force the bottom panel into the cavity. As the carton,
specifically the bottom wall panel, is pushed further into the cavity of
the forming fixture, the 60.degree. forming faces cause the side wall
panels with the backfold web panels to start to fold inwardly before the
other pair of side wall panels. The backfold web panels, connected to the
other, second pair of side walls along the angled cut, fold inwardly as
the first folded side wall panels approach vertical, becoming parallel to
the second pair of side walls and forming the corner closing webs. When
the carton bottom is in contact with the base of the fixture, the backfold
corner webs automatically lock the side panels in place and dose the
corners of the carton. The open top of the carton is closed by folding the
major and minor top closure flaps toward each other into overlaid relation
and inserting the locking tab into the tab receiving slot, lifting the tip
of the tab until the wings are out.
An important advantage of the present invention is that it combines
specific package manufacturing and shipping advantages, such as cost
efficient production and shipment in a flattened state, with specific
point of use advantages, such as adequate protection of the contents,
enhanced strength, and easy opening. The carton of the present invention
may be used with suitable supplemental packaging means such as
thermoplastic shrinkwrap or other wrappings, either inside or outside the
carton walls.
Even though the carton of the present invention adequately protects a food
item during handling or distribution thereof, it provides for easy opening
at the point of use. The carton, particularly the blank therefor, may be
adapted easily to reconfigure the carton to accommodate various food items
or consumer goods and different sizes of food items.
Other advantages of the present invention include the ability of the
packages to be erected or formed during the process of placing the
contents in the carton, and the ability to easily lock or seal the carton
after filling. The carton of the present invention eliminates the shipment
of voids which are prevalent when dealing with the widely used clamshell
type cartons.
Other objects and advantages of the present invention will become more
fully apparent and understood with reference to the following
specification and to the appended drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view depicting the inside and profile of the die-cut
blank for forming the carton of the present invention, prior to erection;
FIG. 2 is a top plan view depicting a second embodiment of the die-cut
blank;
FIG. 3 is a perspective view of the forming fixture apparatus of the
present invention, and also depicts an initial step in erecting the carton
of the present invention;
FIG. 4 is a perspective view depicting another step in erecting the carton,
also depicting a food item in phantom;
FIG. 5 is a perspective view depicting the carton side walls fully erected,
but with the top open;
FIG. 6 is a perspective view depicting the second embodiment of the carton
fully erected, filled and closed and prior to removal from the fixture
FIG. 7 is a perspective view of a fully erected, filled and dosed carton
removed from the fixture;
FIG. 8 is a perspective view depicting the die-cut blank of FIG. 1 in the
forming fixture and ready to be locked;
FIG. 9 is a perspective view thereof depicting an initial step in locking
the carton;
FIG. 10 is a perspective view depicting the final step in locking the
carton;
FIG. 11 is a top plan view of the forming fixture of the present invention
with an assembled carton position therein;
FIG. 12 is a section along line 12--12 of FIG. 11, with a portion broken
away;
FIG. 13 is a section along line 13--13 of FIG. 11, with a portion broken
away;
FIG. 14 is a perspective view depicting an initial step in the opening of
the carton formed from the blank depicted in FIG. 2;
FIG. 15 is a perspective view of the opened carton and the contents
therein;
FIG. 16 is a perspective view depicting an initial step in the opening of
the carton formed from the blank depicted in FIG. 1; and
FIG. 17 is a perspective view of a fully opened carton.
FIG. 18 is a pictorial view of a likely commercial embodiment of the
fixture of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1, a blank 20 in accordance with the present invention is
formed by a predetermined pattern of fold scorelines, perforated or cut
fold scorelines, and cuts, scores and free edges. In the drawings, double
lines indicate fold scorelines and single solid or single dashed lines
indicate cuts, scores or free edges.
The blank 20 has a polygonal, square bottom wall panel 22 formed and
defined by cut fold scorelines 24, 26, 28, 30. The foldlines 24, 28 are
opposed and parallel with respect to each other, and are generally
perpendicular to the parallel bottom wall panel edge foldlines 26, 30. The
intersection of the foldlines 24, 26, 28, 30 form the periphery of the
bottom wall panel 22 and also form bottom wall panel corners 32, 34, 36,
38.
The blank 20 includes a first pair of side wall panels, including side wall
panel 40 and side wall panel 42, foldably or hingedly connected to the
bottom panel 22 at foldlines 30, 26, respectively. The side wall panels
40, 42 have a free edge 44, 46, respectively, parallel to the foldlines
30, 26 at which they are attached to the bottom panel 22. The sides of the
side wall panel 40 are formed by foldlines 48, 50 which are collinear with
the foldlines 28, 24, respectively, forming two of the four side edges of
the bottom panel 22. Similarly, the sides of the side wall panel 42 are
defined by foldlines 52, 54 which are collinear with bottom panel edge
foldlines 28, 24, respectively.
The blank 20 for forming the carton of the present invention includes
another, second pair of generally rectangular side wall forming panels,
including side wall panel 56 and side wall panel 58. The side wall panels
56, 58 are connected to the bottom panel 22 along foldlines 28, 24,
respectively. A first outer, overlapping cover forming panel 60 is
foldably connected to the side wall panel 56 at a fold scoreline 62. The
cover forming panel 60 includes a tab receiving opening 64 adjacent its
free edge or end 66. The opening 64 has expanded ends 65.
An inside or underlying cover forming panel 68 is foldably connected to the
side wall 58 at a foldline 70. The free edge 72 of the cover forming panel
68 includes a generally central relieved area 74. A generally triangular
closure tab 76 is foldably connected to the cover forming panel 68 along a
connection foldline 78 in the generally central region of the relieved
area 74. The closure tab 76 includes a tab center defined by angular
closure fold scorelines 80. A pair of closure tab wings 82, 84 are
foldably connected to the closure tab 76 along the foldlines 80. The wings
82, 84 are separated from the cover forming panel 68 by cut slits 86, 88
which join with the foldline 78. The free cut side edges 90 of the side
wall panel 56 and outside cover panel 60 are collinear with respect to the
free, cut side edges 92 of the side wall panel 58 and the inside cover
forming panel 68.
As illustrated, the length of the opening 64 is greater than the length of
the scoreline 78 and the width dimensions of the opening 64 in the area of
the ends 65 are greater than the maximum width dimension of the wings 82,
84 as measured along a line perpendicular to the foldlines 80. This
enables the tab 76 to be easily and quickly inserted into and removed from
the opening to closed and open the lock means.
With continued reference to FIG. 1, the side wall panels 40, 42 include
backfolding support web panels 94, 96 and 98, 100, respectively. The
backfolding support web panels 94, 96 are foldably connected to side wall
panel 40 along foldlines 48, 50, respectively, and have an outermost free
edge 102 parallel to the foldlines 48, 50. The web panels 94, 96 are
foldably connected to the side wall panels 56, 58 at angled cut fold
scorelines 104, 106, respectively. The cut lines 104, 106 extend from the
corners 38, 32 of the bottom wall panel 22 at approximately a 45.degree.
angle. Similarly, the backfolding support web panels 98, 100 are foldably
connected to side wall panel 42 along foldlines 54, 52, respectively, and
are foldably coupled to side wall panels 56, 58 along angled cut fold
scorelines 108, 110 extending from corners 34, 36 at approximately a
45.degree. angle. The backfolding support web panels 98, 100 have free
edges 112, parallel to foldlines 52, 54 and collinear with the free edges
102 of the backfolding web support panels 94, 96.
Referring to FIGS. 11-13, the erecting or forming fixture 120 of the
present invention includes a generally fiat base 122. The upper surface of
the base 122 defines a package support surface 123. Preferably the support
surface 123 has a size and configuration approximating the size and
configuration of the carton bottom panel 22. Four generally tubular
support blocks, including two long blocks 124, 126 (depicted in FIG. 13)
and two short blocks 128, 130 (depicted in FIG. 12) support a flat curb
plate 132 parallel to and above the base 122. In the preferred embodiment,
the blocks 124, 126, 128 and 130 are arranged in a generally square
configuration with the blocks 124 and 126 being spaced from one another
and generally parallel to form one of the opposing sides of the
configuration and the blocks 128 and 130 being spaced from one another and
generally parallel to form the other of the opposing sides of the
configuration. Each of the blocks 124 and 126 is generally perpendicular
to each of the blocks 128 and 130.
Each of the blocks 124 and 126 include inner carton forming surface 131
(FIGS. 11 and 13), and each of the blocks 128 and 130 include an inner
carton forming surface 133 (FIGS. 11 and 12). As illustrated best in FIGS.
12 and 13, the package forming surfaces 131 and 133 extend upwardly from,
and at generally right angles to the carton support surface 123.
Preferably, the height of the surfaces 131, 133 (measured by the distance
such walls extend above the surface 123) should be greater than about one
fourth the height of the finished package defined by the length of the
fold lines 48, 50, 52 and 54 (FIG. 1) and less than about three fourths of
such height. In the preferred embodiment, each of the carton forming
surfaces 131 and 133 extend substantially the entire length of the square
configuration defined by the blocks 124, 126, 128 and 130.
In the preferred embodiment, the long blocks 124, 126 extend substantially
across the entire base 122 such that its ends 137 extend to the outer
edges of the base 122 and the curb plate 132 as illustrated best in FIG.
12. In contrast, as shown in FIG. 13, the blocks 128 and 130 have ends 135
which are spaced inwardly from the carton forming surfaces 131 of the
blocks 124 and 126. Accordingly, the blocks 128 and 130 form a slot 162
between their ends 135 and the package forming surface 131. The preferred
embodiment illustrates the carton forming walls 131 of the tubes 124 and
126 as extending across the entirety of the base 122 from one edge to the
other; however, the advantage of the invention can be achieved as long as
the surface 131 is sufficiently long to perform its carton forming
function. The same is true for the carton forming surfaces 133, except for
the provision of the slots 162. It is contemplated, however, that the
surfaces 133 could be shorter provided they are sufficiently long to
perform their carton forming function. In any event, since the ends of the
blocks 128 and 130 define the slot 162, they must not extend beyond the
surfaces 131.
The fixture 120 further includes two pairs of opposed, angled blocks
including a first pair of opposed angled blocks 136, 138 supported by the
blocks 128 and 130 and a second pair of angled blocks 140, 142 supported
by the blocks 124, 126. All of the blocks 136, 138, 140, 142 may be
substantially hollow, as are the support tubes 124-130, or may be formed
as relatively thin, solid pieces of appropriate material, or filled with
appropriate material.
Referring to FIG. 13, each of the opposed angled blocks 140, 142 include an
angled package forming surface 144, 146, respectively, angled at
approximately a 45.degree. angle with respect to the base 122. Referring
to FIGS. 11 and 12, each of the angled blocks 140, 142 include end or side
edges 150. Referring to FIG. 12, each of the opposed angled blocks 136,
138 include an angled package surface 154, 156, respectively, and,
referring to FIGS. 11 and 13, side or end walls 158. The forming faces
154, 156 form an angle of approximately 60.degree. with respect to the
base 122. The blocks 124-130, and specifically their respective package
forming surfaces 131, 133, form a carton bottom receiving cavity,
indicated generally at 161 (FIG. 3). Similar to the blocks 128, 130, the
ends 158 of the angled blocks 136, 138 are spaced inwardly from the
surface 133 to accommodate the slot 162. The curb plate 132 is also
provided with appropriate positioned recesses 164 to accommodate and help
define the slots 162. A transition portion guide or edge 143 is formed
between the carton forming surfaces 131 and their corresponding carton
forming surfaces 144, 146 and between the carton forming surfaces 133 and
their corresponding carton forming surfaces 154, 156. Specifically, the
guide edge is formed between the surface 131 and the surfaces 144, 146 and
the guide edge is formed between the surface 133 and the surfaces 154,
156.
The forming fixture 120 may be made of suitably rigid material including
plastics, metals, and/or metal alloys. A preferred material for making the
forming fixture 120 of the present invention is stainless steel. FIG. 18
depicts a likely commercial embodiment of the fixture 120 wherein the
carton forming surfaces 131, 133 and 144, 146, 154, 156, and the base 122,
are provided by four single pieces 181 of a single thickness or layer of
suitable material approximately 1/16 of an inch thick. The pieces 181 are
connected to the base 122 by conventional means. Adjacent pieces are
spaced from one another at their edges.
The fixture structure can also be characterized as having a carton support
surface 123, a first guide edge comprised of the edge portions 141, 143
and a second guide edge defined by the outer edge portions of the surfaces
144, 146 and 154, 156. As illustrated best in FIGS. 12 and 13, the first
guide edge is spaced above and extends generally parallel to the support
surface 123. Preferably the first edge defines a configuration
approximating the size and configuration of the bottom wall of the carton.
The second guide edge is spaced above and outwardly from the first guide
edge. Each of the first guide edge portions and each of the second guide
edge portions are spaced from adjacent first and second guide edge
portions to accommodate the backfold web of the formed carton. Further,
two of the opposed second edge portions are positioned so that they engage
the carton being formed prior to the other opposed second guide edges.
This causes two of the carton sides to be folded inwardly prior to the
other.
Referring to FIG. 2, a second embodiment blank 180 is depicted. The blank
180 for forming the second embodiment of the carton of the present
invention is substantially similar to the blank 20 depicted in FIG. 1, and
the similar features and structure thereof are identified with reference
numerals in common with the blank 20 depicted in FIG. 1. Additionally, the
blank 180 includes a side wall panel 182 (comparable and corresponding to
side wall panel 56 of FIG. 1) foldably connected to the bottom panel 22
along the foldline 28. The side wall panel 182 includes adhesive areas
184, 186. The blank 180 also includes a single cover wall panel 188,
conforming in shape to the bottom wall panel 22 and foldably connected to
the side wall panel 58 along foldline 70. A glue panel 190 is foldably
connected to the cover panel 188 along a fold scoreline 194. A pull tab
192 is foldably coupled to the glue panel 190 at the foldline 194. The
pull tab 192 extends for part of the length of the panel 190.
With reference to FIGS. 3-6, the use of the forming fixture 120 of the
present invention, in combination with blank 20, at the point of use is
depicted. The forming fixture 120 may be placed permanently or movably on
a suitable surface such as a countertop, tabletop or other suitable
location in a restaurant. Referring to FIG. 3, initially the blank 20 is
superimposed above the receiving cavity 161 of the forming fixture 120
with the bottom panel 22 generally aligned with the carton support surface
123. The side walls 40, 42 of the blank 20 including the backfolding
support web panels 94, 96, 98, 100 are positioned over the 60.degree.
forming walls 136, 138. The two remaining side wall panels 56 are
positioned over the 45.degree. forming walls 140, 142.
Referring to FIG. 4, a sandwich S, depicted in phantom, is placed on the
bottom panel 22. The weight of the sandwich S will begin to move or force
the bottom panel 22 downwardly into the bottom receiving cavity 161 of the
forming fixture 120. Because the side wall panels 40, 42 with the
backfolding web support panels 94, 96, 98, 100 are positioned over the
60.degree. forming walls 136, 138, they will begin to fold upwardly in the
direction of arrow A before the other two side wall panels 56, 58.
Simultaneously, the backfolding web support panels 94, 96, 98, 100 begin
to fold outwardly along foldlines 48-54 and along the angled cut foldlines
106, 108. As downward pressure into the cavity 161 is continued, the
remaining side wall panels 56, 58 to which the cover panels 68, 60, are
attached, begin to move upwardly and inwardly in the direction of arrow B,
and the webs 202, comprised of the web panels 94, 96, 98, 100 and part of
the side walls 56, 58, are received in the slots 162.
Referring to FIG. 5, when the bottom panel 22 of the now partially erected
carton 200 contacts the support surface 123 of the forming fixture 120,
the side wall panels 40, 42, 56, 58 will be perpendicular to the bottom
wall 22. The backfolding web support panels 94-100 are completely
backfolded to form a double thickness corner web 202 at each corner of the
carton 200. The webs 202 are comprised of the web support panels 94-100
and the side wall panels 56, 58. The webs 202 are generally coplanar with
the side walls 56, 58 and are generally perpendicular with respect to the
other two opposed parallel side walls 40, 42 of the carton 200. The webs
202 are received in the slots 162 of the forming fixture 120.
Referring to FIGS. 8-10, the closing of the erected carton 200 formed from
blank 20 is depicted. Specifically, referring to FIG. 8, the inside cover
forming panel 68 and the outside cover forming panel 60 are folded
downwardly toward the contents of the carton 200. Referring to FIG. 9, as
the panels 68, 60 approach a coplanar relationship across the previously
open top of the carton 200, the closure tab 76 may be inserted into the
tab receiving opening 64. The closure tab 76 is raised in the direction of
arrow C, thereby allowing the wings 82, 84 to extend out beyond the edges
of the opening 64 on both sides thereof. Referring to FIG. 10, the tab 76
can then be folded downwardly along arrow D to lie generally parallel and
closely adjacent the top wall, indicated generally at 204, of the now
dosed and locked carton 200.
Referring to FIG. 16, to open the carton 200, the tab 76 is first lifted in
the direction of arrow E. The wings 82, 84 are folded about the foldlines
80 toward each other, until they overlie the expanded ends 65 of the
opening 64. The outer cover forming panel 60 is raised until the tab 76
passes through the opening 64. Referring to FIG. 17, the side walls 40,
42, 56, 58 may be folded downwardly about the foldlines 24-30 allowing
complete access to the sandwiches contained in the now opened carton 200.
With specific regard to opening the carton 200 formed from the blank 180,
referring to FIGS. 7, 14, and 15, depicting a filled and dosed carton, the
pull tab 192 is pulled outwardly in the direction of arrow F rupturing the
adhesive attachment between the glue panel 190 and side wall 182, and the
adhesive areas 184, 186. The top cover panel 188 may then be rotated
upwardly around the foldline 70 and the carton 200 can be unfolded to the
position depicted in FIG. 15. The fully opened carton 200, formed from
either blank 20, 180, will be substantially as illustrated in FIG. 17.
One of the advantages of the carton 200 of the present invention may be
appreciated by reference to FIG. 15. The backfold webs 202 are connected
to the side walls 182, 58 along angled perforated foldlines 104-110, and
to side wall panels 40, 42 along foldlines 48, 50 and 52, 54,
respectively. Consequently, even if a relatively heavy sandwich, such as a
hamburger, is contained in the carton 200, rough handling of the carton
200 will not cause the side walls 40, 42, 182, 58 of the carton 200 to
move outwardly. Another advantage of this backfolded web structure 202 is
that the corners of the carton 200 are substantially dosed, thereby
preventing cooling and contamination. Yet another advantage of the carton
200 is depicted in FIG. 17, wherein the carton 200 is unfolded to lie
substantially flat for supporting the food item while it is being
consumed.
The second embodiment blank 180 of the present invention may be partially
glued or tubed into a generally hollow, cylindrical, tubular configuration
(not shown) by the manufacturer. For example, in the second embodiment
blank 180, the adhesive areas 184, 186 would be activated or adhesive
would be applied at the point of manufacture and the carton 200 would be
shipped in a generally flattened, tube-like form. At the point of use the
carton 200 would be erected to form an open-ended tube and a sandwich
would be inserted in one of the two open ends, which could then be closed
either by pushing them inwardly by hand or by placing the filled carton
200 in the fixture 120, aligning the backfold webs 202 with the slots 162
and pushing the carton 200 into the fixture 120 whereby the side walls 40,
42 would fold dosed as they come in contact with the 60.degree. angle
forming walls 136, 138, closing the carton 200 into the shape depicted in
FIGS. 6 and 7.
A number of variations of the present invention can be accomplished within
the scope of the invention. For example, the location, size and shape of
the cover locking structure associated with the blank 20 (or 180) may be
varied as desired. The carton 200 can be adapted to contain products of
various sizes and shapes. Portions of the carton 200 may be curved rather
than angled and the depicted fold scorelines may be perforated or cut as
desired. The carton 200 may be formed of any appropriate caliper
paperboard or other stock material, be printed with desired graphics or
indicia, and may be provided with desireable characteristics such as
resistance to moisture by applying appropriate coatings to the interior or
exterior surfaces.
Although a description of the preferred embodiment has been presented, it
is contemplated that various changes, including those mentioned above,
could be made without deviating from the spirit of the present invention.
It is therefore desired that the present embodiment be considered in all
respects as illustrative, not restrictive, and that reference be made to
the appended claims rather than to the foregoing description to indicate
the scope of the invention.
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